Rotary knob assembly

ABSTRACT

A rotary knob assembly and methods for forming and controlling friction effecting features of the knob assembly are disclosed. The knob assembly includes a mounting structure and a knob. The knob is rotatably coupled to a bezel of the mounting structure. The knob includes a stabilizer, a guide member, and a retainer having a patterned surface. At least a portion of the stabilizer is disposed between the bezel and the retainer to maintain an axial position and a radial position of the knob. A detent formed on the guide member cooperates with a patterned surface of the retainer to provide a haptic feedback to a user.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 13/160,998 filed Jun. 15, 2011, hereby incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The invention relates to a rotary knob assembly, and more particularlyto a rotary knob assembly for an instrument panel, and a method by whichthe rotary knob assembly is formed and tuned.

BACKGROUND OF THE INVENTION

Presently known automotive vehicle instrument panels have rotary controlknobs to effect an operation of electrical equipment associated with thevehicle. These rotary control knobs may be manually moved to effect anoperation of vehicle lights, radio volume, heater, or air conditioner,for example. One configuration of the rotary control knob an encoder orpotentiometer with haptics incorporated therein.

Typically, interfaces between the knob and the bezel of the rotary knobhave close tolerances. Despite the close tolerances, the rotary knobsmay have a loose or wobbly feel to a user and an undesired noise can beproduced due to a rattle between the knob and the bezel. Because of asize of the bezel, a molding process thereof results in a wide variationof bezels produced. In particular, a current mold assembly of themolding process has difficulty producing repeatable concentric guideposts on the bezel. To tune current rotary knobs, a concentricity of theguide post of the bezel is tuned. However, a tuning of the current moldassembly of the bezel is difficult.

Accordingly, it would be desirable to produce a knob assembly andmethods for forming and tuning thereof, wherein a wobble of the knobassembly is minimized and a tuning of a mold assembly for the knobassembly is easily tuned.

SUMMARY OF THE INVENTION

In concordance and agreement with the present invention, a knob assemblyand methods for forming and tuning thereof, wherein a wobble of the knobassembly is minimized and a tuning of a mold assembly for the knobassembly is easily tuned, has surprisingly been discovered.

In one embodiment, the knob assembly comprises: a mounting structureincluding a bezel; and a knob rotatably coupled to the mountingstructure, the knob including a stabilizer and a retainer having apatterned surface, wherein at least a portion of the stabilizer isdisposed between the bezel and the retainer to maintain an axialposition and a radial position of the knob.

The invention also provides a method for forming a knob assemblycomprises the steps of: (a) providing a cavity insert for a moldassembly; (b) providing an inner core insert for the mold assembly; (c)providing an outer core insert for the mold assembly; (d) positioningthe cavity insert, the inner core insert, and the outer core insert toform a mold cavity within the mold assembly for receiving a moltenmaterial therein; and (e) introducing the molten material into the moldcavity, wherein at least one of the cavity insert, the inner coreinsert, and the outer core insert is at least one of modifiable andreplaceable, and wherein the cavity insert, the inner core insert, andthe outer core insert form friction affecting features of the knobassembly.

The invention also provides a method for tuning a knob assemblycomprising the steps of: (a) providing a plurality of inserts to form amold cavity for a mold assembly, wherein at least one of the inserts isat least one of modifiable and replaceable; (b) electing at least one ofthe inserts to be at least one of modified and replaced; and (c) atleast one of modifying and replacing the at least one of the inserts tocontrol friction affecting features of the knob assembly.

DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description of a preferred embodiment when considered in thelight of the accompanying drawings in which:

FIG. 1 is an exploded rear perspective view of a rotary knob assemblyaccording to an embodiment of the invention;

FIG. 2 is a cross-sectional view of the assembled rotary knob assemblyillustrated in FIG. 1;

FIG. 3 is a cross-sectional view of a rotary knob assembly according toanother embodiment of the invention;

FIG. 4 is an exploded front perspective view of a mold assembly forforming a retainer of at least one of the rotary knob assembliesillustrated in FIGS. 1-3, showing the retainer therein;

FIG. 5 is a cross-sectional view of the assembled mold assemblyillustrated in FIG. 4;

FIG. 6 is an exploded front perspective view of a mold assembly forforming a stabilizer of the rotary knob assembly illustrated in FIGS.1-2, showing the stabilizer therein; and

FIG. 7 is a cross-sectional view of the mold assembly illustrated inFIG. 6.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description and appended drawings describe andillustrate various exemplary embodiments of the invention. Thedescription and drawings serve to enable one skilled in the art to makeand use the invention, and are not intended to limit the scope of theinvention in any manner.

FIGS. 1-2 show a rotary knob assembly 10 according to an embodiment ofthe invention. Although the knob assembly 10 shown and described asbeing used with a vehicle instrument panel, it should be understood thatthe knob assembly 10 can be used as an input device for any type ofcomponent such as hand-held devices or non-vehicular electricalequipment, for example. The knob assembly 10 includes a mountingstructure 20, a guide member 50, and a knob 70. As shown, a single knob70 is received on the mounting structure 20. However, the mountingstructure 20 can be formed to receive as many knobs 70 as desired.

The mounting structure 20 shown includes a contact board 22, anelastomeric switch mat 24, and a bezel 26. The contact board 22 may be aprinted wiring board (PWB) or a printed circuit board (PCB), or anysuitable device that permits engagement and disengagement of anelectrical connection. The contact board 22 shown is a rigid substratehaving conductive traces (not shown) formed thereon or therein. It isunderstood that the contact board 22 could be semi-rigid or flexible ifdesired. The conductive traces can be formed on the contact board 22using a variety of process known in the art such as wire soldered toappropriate connections, copper traces printed on mylar, or conductiveink applied to a hybrid ceramic, for example. The switch mat 24 istypically formed of molded silicone rubber. However, it is understoodthat the switch mat 24 can be formed from any suitable material asdesired. As illustrated, a plurality of spaced-apart arcuate-shapedopenings 30 is formed in the switch mat 24 to receive correspondingportions 32 of the bezel 26 therethrough. The bezel 26 can be affixed toan electronic instrument panel (not shown) or can be integrally formedas part of the electronic instrument panel, if desired. The contactboard 22, the switch mat 24, and the bezel 26 can be secured together byany means as desired such as by fasteners, an adhesive, an interferencefit, and the like, for example.

The mounting structure 20 further includes the guide member 50 disposedthereon. The guide member 50 is fixedly coupled to the bezel 26 so as toremain in position during a rotation of the knob 70. The guide member 50can be secured to the mounting structure 20 by any means as desired suchas by a heat staking process, snap or interference fit, fasteners,clips, adhesive, and the like, for example. The guide member 50 shownhas a generally circular shape and includes an inner ring 52 having acentral aperture 53 coupled to an outer ring 54. The central aperture 53permits the guide member 50 to be disposed on the bezel 26 surrounding aguide post 56 thereof. The inner ring 52 further includes an annulargroove 58 formed therein. The groove 58 forms an annular raised portion60 extending towards the knob 70. The outer ring 54 of the guide member50 includes at least one detent 62 formed thereon. The guide member 50shown is produced from any suitable material such as steel, for example.The guide member 50 may also include a lubricant (e.g. grease) appliedthereto to minimize surface friction.

The knob 70 is coupled to the mounting structure 20 for rotationalmovement on the mounting structure 20 about a central axis X. Asillustrated in FIG. 1, the knob 70 includes a retainer 72, a stabilizer74, an outer housing 76, and an aesthetic feature 78 such as achrome-plated accent piece, for example. Additional or fewer aestheticfeatures 78 than shown can be disposed on or integrated into the knob 70as desired. As shown in FIG. 2, the retainer 72 is rotatably disposedbetween the guide member 50 and the stabilizer 74. A first end 80 of theretainer 72 is crenellated having a series of spaced-apart teeth 82. Theteeth 82 can have any shape and size as desired such as square,rectangular, triangular, semicircular, and the like, for example.

A radially outwardly extending skirt 84 is formed on the retainer 72adjacent the crenellated first end 80. The skirt 84 includes an innerportion having an annular array of grooved landings 86 which receive andcooperate with the raised portion 60 of the guide member 50 to maintaina radial position of the retainer 72, and therefore the knob 80. Anouter portion of the skirt 84 includes a patterned surface. It isunderstood that the term “patterned surface” used herein refers to asurface including any shapes and configurations thereof, as well as asubstantially planar surface. As shown in FIG. 1, the patterned surfaceis defined by a plurality of sinusoidal peaks 88 and troughs 90. Thepeaks 88 and troughs 90 slidingly contact the stationary detent 62 ofthe guide member 50 during the rotation of the knob 70 to produce andtransmit a desired haptic feedback to a user. The retainer 72 can beformed from any suitable material such as a polycarbonate (PC) material,an acrylonitrile butadiene styrene (ABS) material, a polyoxymethylene(POM) material, a thermoplastic polyester elastomer material, acombination thereof, and the like, for example.

As illustrated in FIG. 2, the stabilizer 74 is disposed between a guidepost 54 of the bezel 26 and a second end 92 of the retainer. Thestabilizer 74 shown is fixedly coupled to the bezel 26 so as to remainin position during the rotation of the knob 70. It is understood thatthe stabilizer 74 can be coupled to the bezel 26 by any means as desiredsuch as by retention feet 93, an interference fit, fasteners, adhesive,and the like, for example. A bottom surface of the stabilizer 74 abuts aledge 94 formed in the retainer 72 to urge the retainer 72 onto theguide member 50 and to maintain an axial position of the retainer 72,and therefore the knob 70. The stabilizer 74 may include an array ofprotuberances (not shown) formed on the lower surface to minimizefriction between the stabilizer 74 and the retainer 72 during therotation of the knob 70. The stabilizer 74 is substantially ring shapedand includes an annular array of tabs 95 formed on an outer surfacethereof. The tabs 95 abut an inner surface of the retainer 72 to furthermaintain a radial position of the retainer 72, and therefore the knob70. The tabs 95 further minimize friction between the stabilizer 74 andthe retainer 72. It is understood that the stabilizer 74 can be formedwithout the tabs 95 if desired. Because the stabilizer 74 maintains theaxial and radial positions of the retainer 72, an undesired wobble ofthe knob 70 is minimized.

As shown in FIG. 1, a plurality of rectangular shaped openings 96 isformed in the stabilizer 74. The openings 96 permit a flexing of thestabilizer 74, and thereby control an axial load on the retainer 72.Thus, an amount of torque needed to rotate the knob 70 is dependent on asize and shape of the openings 96. For example, smaller openings 96permit less flexing of the stabilizer 74, and thereby increase the axialload on the retainer 72. Therefore, the amount of torque needed torotate the knob 70 is also increased. Conversely, larger openings 96permit more flexing of the stabilizer 74, and thereby decrease the axialload on the retainer 72. Therefore, the amount of torque needed torotate the knob 70 is also decreased. It is understood that each of theopenings 96 can have any size and shape as desired to obtain a desiredtorque requirement for the knob 70. It is further understood that thestabilizer 74 can be formed from any suitable material such as apolycarbonate (PC) material, an acrylonitrile butadiene styrene (ABS)material, a polyoxymethylene (POM) material, a thermoplastic polyesterelastomer material, a combination thereof, and the like, for example.

The outer housing 76 is generally cylindrical and includes a first end98 and a second end 100. As shown in FIG. 2, the first end 98 of theouter housing 76 circumscribes the retainer 72 and is coupled thereto.It is understood that the outer housing 76 can be coupled to theretainer 72 by any means as desired such as fasteners, clips, a snap orinterference fit, adhesive, and the like, for example. The second end100 of the outer housing 76 receives the aesthetic feature 78 thereon.The aesthetic feature 78 and the second end 100 of the outer housing 76circumscribe the guide post 54 of the bezel 26 forming an interstitialspace therebetween to permit rotational movement of the knob 70. Theouter housing 76 can be formed from any suitable material such as apolycarbonate (PC) material, an acrylonitrile butadiene styrene (ABS)material, a combination thereof, and the like, for example.

The knob assembly 10 further includes a sensor assembly (not shown)including at least one sensor (not shown) for detecting a rotationposition of the knob 70 relative to the mounting structure 20 bydetecting a presence of the teeth 82 formed on the retainer 72. Thesensor is in electrical communication with the contact board 22. Forexample, the sensor can be the conductive traces formed on the contactboard 22 or separate components individually mounted on the contactboard 22. The contact board 22 transmits a signal from the sensordirectly to a device or system associated with the knob assembly 10 (notshown), or to a controller (not shown) for controlling an operation ofdevice or system.

In operation, the user rotates the knob 70 to provide input forcontrolling the device or system associated with the knob assembly 10.For example, the device or system could be a climate control system, anaudio and video system, a navigation system, and the like, for example.The knob 70 may be manually rotated by the user, or alternatively,rotated with assistance of an electrical motor based on input from theuser entered into a controller. As the knob 70 is rotated about the axisX, the teeth 82 of the retainer 72 travel along a circular path, passingthrough a sight line of the sensor of the sensor assembly. The sensordetects a change in position of the knob 70 relative to the mountingstructure 20. This detection by the sensor causes the control board 22to generate and transmit a signal to the device or system, or to thecontroller which controls the operation of the device or system.

When the knob 70 is manually rotated, the outer portion of the skirt 84of the retainer 72 slidingly travels along the outer ring 54 of theguide member 50. The detent 62 formed in the outer ring 54 contacts thepatterned surface of the outer portion of the skirt 84 to produce thedesired feedback, which is transmitted to the user. Typically, thedesired feedback is associated with particular setting of the device orsystem.

FIG. 3 shows a rotary knob assembly 110 according to another embodimentof the invention. Although the knob assembly 110 shown and described asbeing used with a vehicle instrument panel, it should be understood thatthe knob assembly 110 can be used as an input device for any type ofcomponent such as hand-held devices or non-vehicular electricalequipment, for example. The knob assembly 110 includes a mountingstructure 120, a guide member 150, and a knob 170. As shown, a singleknob 170 is received on the mounting structure 120. However, themounting structure 120 can be formed to receive as many knobs 170 asdesired.

The mounting structure 120 shown includes a contact board 122, anelastomeric switch mat 124, and a bezel 126. The contact board 122 maybe a printed wiring board (PWB) or a printed circuit board (PCB), or anysuitable device that permits engagement and disengagement of anelectrical connection. The contact board 122 shown is a rigid substratehaving conductive traces (not shown) formed thereon or therein. It isunderstood that the contact board 122 could be semi-rigid or flexible ifdesired. The conductive traces can be formed on the contact board 122using a variety of process known in the art such as wire soldered toappropriate connections, copper traces printed on mylar, or conductiveink applied to a hybrid ceramic, for example. The switch mat 124 istypically formed of molded silicone rubber. However, it is understoodthat the switch mat 124 can be formed from any suitable material asdesired. As illustrated, a plurality of spaced-apart arcuate-shapedopenings 130 is formed in the switch mat 124 to receive correspondingportions 132 of the bezel 126 therethrough. The bezel 126 can be affixedto an electronic instrument panel (not shown) or can be integrallyformed as part of the electronic instrument panel, if desired. Thecontact board 122, the switch mat 124, and the bezel 126 can be securedtogether by any means as desired such as by fasteners, an adhesive, aninterference fit, and the like, for example.

The mounting structure 120 further includes the guide member 150disposed thereon. The guide member 150 is fixedly coupled to the bezel126 so as to remain in position during a rotation of the knob 170. Theguide member 150 can be secured to the mounting structure 120 by anymeans as desired such as by a heat staking process, snap or interferencefit, fasteners, clips, adhesive, and the like, for example. The guidemember 150 shown has a generally circular shape and includes an innerring 152 having a central aperture 153 coupled to an outer ring 154. Thecentral aperture 153 permits the guide member 50 to be disposed on thebezel 26 surrounding a guide post 156 thereof. The inner ring 152 shownfurther includes an annular groove 158 formed therein. It is understood,however, that the inner ring 152 can be substantially planar if desired.The groove 158 forms an annular raised portion 160 extending towards theknob 170. The outer ring 154 of the guide member 150 includes at leastone detent 162 formed thereon. The guide member 150 shown is producedfrom any suitable material such as steel, for example. The guide member150 may also include a lubricant (e.g. grease) applied thereto tominimize surface friction.

The knob 170 is coupled to the mounting structure 120 for rotationalmovement on the mounting structure 120 about a central axis X. The knob170 includes a retainer 172, a stabilizer 174, an outer housing 176, andan aesthetic feature 178 such as a chrome-plated accent piece, forexample. Additional or fewer aesthetic features 178 than shown can bedisposed on or integrated into the knob 170 as desired. As shown, theretainer 172 is rotatably disposed between the guide member 150 and thestabilizer 174. A first end 180 of the retainer 172 is crenellatedhaving a series of spaced-apart teeth 182. The teeth 182 can have anyshape and size as desired such as square, rectangular, triangular,semicircular, and the like, for example.

A radially outwardly extending skirt 184 is formed on the retainer 172adjacent the crenellated first end 180. The skirt 184 includes an innerportion having an annular groove 186 formed therein to militate againstcontact with the inner ring 152 of the guide member 150. An outerportion of the skirt 184 includes a patterned surface. The patternedsurface slidingly contacts the stationary detent 162 of the guide member150 during the rotation of the knob 170 to produce and transmit adesired haptic feedback to a user. The retainer 172 can be formed fromany suitable material such as a polycarbonate (PC) material, anacrylonitrile butadiene styrene (ABS) material, a polyoxymethylene (POM)material, a thermoplastic polyester elastomer material, a combinationthereof, and the like, for example.

As illustrated, the stabilizer 174 is disposed between a guide post 154of the bezel 126 and a second end 192 of the retainer. The stabilizer174 shown is fixedly coupled to the bezel 126 so as to remain inposition during the rotation of the knob 170. It is understood that thestabilizer 174 can be coupled to the bezel 126 by any means as desiredsuch as by retention feet 193, an interference fit, fasteners, adhesive,and the like, for example. The stabilizer 174 abuts a ledge 194 formedin the retainer 172 to urge the retainer 172 onto the guide member 150and to maintain an axial position of the retainer 172, and therefore theknob 170.

The stabilizer 174 is a bearing assembly including an inner track 195,an outer track 196, and a plurality of ball bearings 197 disposedtherebetween. The outer track 196 of the bearing assembly shown is thesecond end 192 of the retainer 172. However, it is understood that theouter track 196 can be a separate, individual component disposed betweenthe bearings 197 and the retainer 172, if desired. The stabilizer 174abuts an inner surface of the retainer 172 to further maintain a radialposition of the retainer 172, and therefore the knob 170. Because thestabilizer 174 maintains the axial and radial positions of the retainer172, an undesired wobble of the knob 170 is minimized. It is understoodthat the tracks 195, 196 and the bearings 197 of the stabilizer 174 canbe formed from any suitable material such as a plastic material or ametal material (e.g. steel), for example. The stabilizer 174 may alsoinclude a lubricant (e.g. grease) applied thereto to minimize frictionwithin the bearing assembly, as well as between the stabilizer 174 andthe retainer 172.

The outer housing 176 is generally cylindrical and includes a first end198 and a second end 200. The first end 198 of the outer housing 176circumscribes the retainer 172 and is coupled thereto. It is understoodthat the outer housing 176 can be coupled to the retainer 172 by anymeans as desired such as fasteners, clips, a snap or interference fit,adhesive, and the like, for example. The second end 200 of the outerhousing 176 receives the aesthetic feature 178 thereon. The aestheticfeature 178 and the second end 200 of the outer housing 176 circumscribethe guide post 154 of the bezel 126 forming an interstitial spacetherebetween to permit rotational movement of the knob 170. The outerhousing 176 can be formed from any suitable material such as apolycarbonate (PC) material, an acrylonitrile butadiene styrene (ABS)material, a combination thereof, and the like, for example.

The knob assembly 110 further includes a sensor assembly (not shown)including at least one sensor (not shown) for detecting a rotationposition of the knob 170 relative to the mounting structure 120 bydetecting a presence of the teeth 182 formed on the retainer 172. Thesensor is in electrical communication with the contact board 122. Forexample, the sensor can be the conductive traces formed on the contactboard 122 or separate components individually mounted on the contactboard 122. The contact board 122 transmits a signal from the sensor to acontroller (not shown) for controlling an operation of a device orsystem associated with the knob assembly 110.

Since operation of the knob assembly 110 shown in FIG. 3 issubstantially similar to the operation of the knob assembly 10 shown inFIGS. 1-2, for simplicity, the operation of the knob assembly 110 willbe as described hereinabove.

Referring now to FIGS. 4-5, a mold assembly 210 for forming the retainer72 for the knob assembly 10 is shown. It is understood that the moldassembly 210 can also be used for forming the retainer 172 if desired.The mold assembly 210 may be used in any known forming process asdesired such as an injection molding process, a casting process, and thelike, for example. The mold assembly 210 includes an outer cavity insert220, a haptic feedback insert 230, an outer core insert 240, and aninner core insert 250. The inserts 220, 230, 240, 250 shown aremodifiable and replaceable. It is further understood that the moldassembly 210 can include other components necessary for the molding ofthe retainer 72 as desired. The inserts 220, 230, 240, 250 cooperate toform a mold cavity 252 shown in FIG. 5. The mold cavity 252 has a shapesubstantially similar to a shape of the retainer 72. It is understoodthat the mold cavity 252 is in fluid communication with a source ofmolten material. The molten material is introduced into the mold cavity252 through a series of gates (not shown) and a sprue (not shown) toform the retainer 72.

The outer cavity insert 220 includes an annular array of protuberances254 which form the grooved landings 86 in the retainer 72. Since thegrooved landings 86, which cooperate with the raised portion 60 of theguide member 50 to maintain the radial position of the knob 70, requiretight tolerances, the protuberances 254 require tight tolerances.Accordingly, the outer cavity insert 220 provides easy access for atuning and a polishing of the protuberances 254 to ensure the desiredradial position of the knob 70 is obtained. A shoulder portion 256 ofthe outer cavity insert 220 receives the haptic feedback insert 230thereon.

The haptic feedback insert 230 includes a patterned surface 258 whichcorresponds to the patterned surface of the skirt 84 of the retainer 72.As shown in FIG. 4, the patterned surface 258 includes a plurality ofpeaks 260 and troughs 262. The peaks 260 and the troughs 262 correspondto the troughs 90 and the peaks 88, respectively, of the retainer 72.The haptic feedback insert 230 provides easy access for a tuning of thepatterned surface 258 or a replacement thereof when a change in thepatterned surface of the retainer 72 is required. Accordingly, the moldassembly 10 can be used to produce various knob assemblies having avariety of haptic feedbacks.

The outer core insert 240 is generally ring shaped and includes ashoulder portion 266 formed therein. The shoulder portion 266circumscribes at least a portion of the haptic feedback insert 230abutting an outer surface 268 thereof to militate against a formation offlash on the skirt 84 of the retainer 72 during the forming thereof. Aninner surface 270 of the outer core insert 240 abuts a first outersurface 272 of the inner core insert 250. The inner core insert 250includes a second outer surface 273 which forms the inner surface of thesecond end 92 of the retainer 72. Since the inner surface of the secondend 92 of the retainer 72, which slidingly contacts the tabs 94 formedon the stabilizer 74 to maintain the radial position of the knob 70requires tight tolerances, the second outer surface 273 of the innercore insert 250 requires tight tolerances. Accordingly, the inner coreinsert 250 provides easy access for a tuning of the second outer surface273 to ensure the desired radial position of the knob 70 is obtained. Athird outer surface of 274 of the inner core insert 250 abuts an innersurface 276 of the outer cavity insert 220.

In operation, the inserts 220, 230, 240, 250 cooperate to form the moldcavity 252. The molten material is then introduced into the mold cavity252. Once the molten material is cooled to form the retainer 72, theinserts 220, 230, 240, 250 are separated. Thereafter, the finishedretainer 72 is removed and disposed in the knob assembly 10. When atuning of the knob assembly 10 is required, at least one of the inserts220, 230, 240, 250 is selected to be modified and/or replaced. Theinserts 220, 230, 240, 250 are modified to control friction surfaces ofthe retainer 72 and then replaced or replaced by another of the sameinserts 220, 230, 240, 250 to control friction surfaces of the retainer72.

Referring now to FIGS. 6-7, a mold assembly 310 for forming thestabilizer 74 for the knob assembly 10 is shown. The mold assembly 310may be used in any known forming process as desired such as an injectionmolding process, a casting process, and the like, for example. The moldassembly 310 includes an inner core insert 320, a pair of outer coreinserts 322, 324, and an inner cavity insert 326. It is understood thatthe mold assembly 310 can include other components necessary for themolding of the stabilizer 74 as desired. The inserts 320, 322, 324, 326cooperate to form a mold cavity 330 shown in FIG. 7. The mold cavity 330has a shape substantially similar to a shape of the stabilizer 74. It isunderstood that the mold cavity 330 is in fluid communication with asource of molten material. The molten material is introduced into themold cavity 330 through a series of gates (not shown) and a sprue (notshown) to form the stabilizer 74.

The inner core insert 320 is substantially disc shaped and includes anupper portion 332 and a lower portion 334. The upper portion 332includes an array of slots 336 formed therein. The upper portion 332abuts the inner cavity insert 326 so that leg members 338 formed on theinner cavity insert 326 are received in the slots 336 thereof. The upperportion 332 of the inner core insert 320 and the inner cavity insert 326cooperate to form a fluid tight seal therebetween. The lower portion 334includes an array of indentations 339 formed therein. The indentations339 form the protuberances on the lower surface of the stabilizer 74. Asshown in FIG. 7, the inner core insert 320 and the inner cavity inset326 are circumscribed by the outer core position inserts 322, 324. Eachof the outer core position inserts 322, 324 includes at least one groove340 formed therein. The grooves 340 form the tabs 95 on the outersurface of the stabilizer 74. Since the tabs 95 of the stabilizer 74,which cooperate with the inner surface of the retainer 72 to maintainthe radial position of the knob 70 require tight tolerances, the grooves340 require tight tolerances. Accordingly, the outer core positioninserts 322, 324 provide easy access for a tuning of the grooves 340 toensure the desired radial position of the knob 70 is obtained. Each ofthe outer core position inserts 322, 324 further includes at least oneprotuberance 342. The protuberances 342 form the openings 96 in thestabilizer 74. Since the openings 96, which control the axial load onthe retainer 72 and determine a torque required to rotate the knob 70require tight tolerances, the protuberances 342 also require tighttolerances. Accordingly, the outer core position inserts 322, 324provide easy access for a tuning of the protuberances 342 to ensure thedesired radial position of the knob 70 is obtained. The inserts 320,322, 324, 326 provide easy access for controlling a concentricity of thestabilizer 74.

In operation, the inserts 320, 322, 324, 326 cooperate to form the moldcavity 330. The molten material is then introduced into the mold cavity330. Once the molten material is cooled to form the stabilizer 74, theinserts 320, 322, 324, 326 are separated. Thereafter, the finishedstabilizer 74 is removed and disposed in the knob assembly 10. When atuning of the knob assembly 10 is required, at least one of the inserts320, 322, 324, 326 is selected to be modified and/or replaced. Theinserts 320, 322, 324, 326 are modified to control friction surfaces ofthe stabilizer 74 and then replaced or replaced by another of the sameinserts 320, 322, 324, 326 to control friction surfaces of thestabilizer 74.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, can make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

What is claimed is:
 1. A method for forming a knob assembly comprisingthe steps of: (a) providing a first cavity insert for a mold assembly;(b) providing a first inner core insert for the mold assembly; (c)providing a first pair of outer core inserts for the mold assembly; (d)positioning the first cavity insert, the first inner core insert, andthe first pair of outer core inserts to form a first mold cavity withinthe mold assembly for receiving a molten material therein; and (e)introducing the molten material into the first mold cavity to form astabilizer of the knob assembly, wherein the first cavity insert, thefirst inner core insert, and the first pair of outer core inserts are atleast one of modifiable and replaceable, and wherein the first cavityinsert, the first inner core insert, and the first pair of outer coreinserts include a groove and a protuberance configured to form frictionaffecting features of the knob assembly.
 2. The method according toclaim 1, wherein the friction affecting features are at least one of aplurality of tabs formed on an outer surface of the stabilizer and aplurality of openings formed in the stabilizer.
 3. The method accordingto claim 1, further comprising the steps of: (a) providing a secondcavity insert for the mold assembly; (b) providing a second inner coreinsert for the mold assembly; (c) providing a second outer core insertfor the mold assembly; (d) providing a haptic feedback insert for themold assembly; (e) positioning the second cavity insert, the secondinner core insert, the second outer core insert, and the haptic feedbackinsert to form a second mold cavity within the mold assembly forreceiving the molten material therein; and (f) introducing the moltenmaterial into the second mold cavity to form a retainer of the knobassembly, wherein at least one of the second cavity insert, the secondinner core insert, the second outer core insert, and the haptic feedbackinsert form friction affecting features of the knob assembly.
 4. Themethod according to claim 3, wherein the friction affecting features areat least one of a plurality of grooved landings formed in the retainerand an inner surface of an end of the retainer.
 5. The method accordingto claim 3, wherein the retainer includes at least one grooved landingformed therein.
 6. The method according to claim 3, wherein thestabilizer includes at least one opening formed therein to control anaxial load on the retainer which determines a torque required to rotatea knob of the knob assembly.
 7. The method according to claim 3, furthercomprising the step of providing a guide member disposed between amounting structure of the knob assembly and a knob of the knob assembly.8. The method according to claim 7, wherein the retainer includes apatterned surface.
 9. The method according to claim 8, wherein a detentis formed on the guide member which cooperates with the patternedsurface of the retainer to produce a desired haptic feedback.
 10. Themethod according to claim 7, wherein a raised portion of the guidemember cooperates with the retainer to maintain a radial position of theknob.
 11. The method according to claim 1, wherein the first pair ofouter core inserts include each of the groove and the protuberance, andwherein at least a portion of the groove is axially spaced from andradially aligned with at least a portion of the protuberance.
 12. Themethod according to claim 3, wherein the stabilizer is configured toinclude an inner track, and further comprising the step of providing anouter track and a plurality of ball bearings on the stabilizer.
 13. Themethod according to claim 12, wherein the retainer forms the outer trackof the stabilizer.
 14. A method for forming a knob assembly comprisingthe steps of: (a) providing a first mold assembly comprising a firstcavity insert, a first inner core insert, and a first pair of outer coreinserts positioned to form a first mold cavity within the first moldassembly, each of the first pair of outer core inserts including agroove and a protuberance formed thereon; (b) introducing a moltenmaterial into the first mold cavity to form a stabilizer of the knobassembly, wherein the groove and the protuberance form frictionaffecting features of the stabilizer; (c) providing a second moldassembly comprising a second inner core insert, a second outer coreinsert, a haptic feedback insert, and a second outer cavity insertpositioned to form a second mold cavity within the second mold assembly;(d) and introducing the molten material into the second mold cavity toform a retainer of the knob assembly; (e) providing a guide memberhaving at least one detent formed thereon; and (f) assembling each ofthe guide member, the stabilizer, and the retainer to a mountingstructure, wherein the retainer is rotatably disposed intermediate theguide member and the stabilizer.
 15. The method according to claim 14,wherein a first one of the friction affecting features is a tab, and thetab abuts an inner surface of the retainer, and a second one of thefriction affecting features is an opening, and permits a flexing of thestabilizer.
 16. The method according to claim 15, wherein the opening isa rectangular shaped opening formed in the stabilizer.
 17. The methodaccording to claim 15, wherein at least a portion of the groove isaxially spaced from and radially aligned with at least a portion of theprotuberance.